MERCEDES-BENZ ML350 1997 Complete Repair Manual

AR68.20-P-2020GH
Removing and installing rear section of center console
18.5.01

MODEL
163.113 /136 /154 /172 /174 as of 1.9.99 up to 31.8.01

P68.20-2492-06

1
Rear cupholder

2
Screw

3
Center console rear section

4
Tab


Remove, install

1
Open rear cupholder (1), release from center

console and fold down

2
Remove screws (2)

3
Unclip rear section (3) at top (arrows)


*115589035900

4
Release tabs (4) at bottom

Danger of breaking.

5
Pull rear section (3) away from center console

6
Unplug connectors for rear window switches

7
Install in reverse order

Long wedge

115 589 03 59 00

Copyright DaimlerChrysler AG 10.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR72.29-P-0001GH
Removing and installing center console switch group
14.2.97

MODEL
163.113 /136 /154 /172 /174 up to 31.8.01

P72.29-0273-05

S21
Center console switch group

Operation no. of operation texts or standard texts and flat rates
Range

Op. no.
Operation text

P
725733
REPLACING SWITCH FOR POWER WINDOW IN CENTER CONSOLE; LOCATION: ............. (AFTER CHECKING)

P
725734
REPLACING SWITCH FOR POWER WINDOW IN CENTER CONSOLE FOR REAR OPERATION; LOCATION .............
(AFTER CHECKING)

P
725760
REPLACING SWITCH FOR POWER WINDOWS (BOTH) IN CENTER CONSOLE FOR LEFT AND RIGHT REAR

DOOR (AFTER CHECKING)


Removal, installation

1
Remove ashtray at front of center console

AR68.20-P-2400GH

2
Unclip center console switch group (S21)

Center console switch group can only be

replaced completely.

3
Install in the reverse order

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AR68.20-P-2310GH
Removing and installing cover at gearshift lever
4.2.97

MODEL
163.113 /136 /154 /172 /174 up to 31.8.01

P68.20-0434-06

1
Plastic frame

2
Covering in front stowage compartment

3
Center console insert

4
Cover

5
Connectors

S21
Center console switch group

Operation no. of operation texts or standard texts and flat rates
Range

Op. no.
Operation text

P
683450
REMOVING AND INSTALLING COVER FOR SHIFT LEVER

P
683455
REPLACING COVER FOR GEARSHIFT LEVER

Remove/install

1
Remove plastic frame (1) upward


*115589035900

2
Remove covering in stowage

compartment (2)

Fastened with pin.

3
Remove center console insert (3)

Remove screws (2 each) from insert floor

4
Press cover (4) out of catch in center console

at rear and sides with long wedge

*115589035900

5
Disconnect connectors (5) from center

console switch group (S21)

6
Install in the reverse order

Long wedge

115 589 03 59 00

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Page 1

AR68.20-P-2370GH
Remove/install armrest lid on center console
15.4.97

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P68.20-0461-06

Illustrated on model 163 up to 31.08.01

1
Stowage compartment

2
Screws

3
Stowage box

4
Screws

5
Armrest cover

P68.20-2544-04

Illustrated on model 163 as of 01.09.01

4
Bolts

5
Armrest cover

6
Access openings

Removing, installing

1.1
Remove storage compartment (1)

Up to 31.08.01: Unclip stowage

compartment (1) from stowage box (3)

2.1
Unscrew screws (2) and remove stowage box

(3)

up to 31.08.01

3
Unscrew screws (4).

4
Remove armrest lid (5)

As of 01.09.01: Insert long wedge into

access openings (6) and loosen retaining lugs.

Long wedge

*115589035900

5
Install in the reverse order

Assembly wedge

115 589 03 59 00

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AR68.20-P-2000GH
Remove/install center console
4.2.97

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P68.20-0447-01 P68.20-0449-01 P68.20-0452-01

1
Housing

2
Screws
S21/15s1

Left rear power window switch

S21/15s2
Right rear power window switch

3

Screws

4
Screws


Remove, Install

1
Remove armrest cover from center console

AR68.20-P-2370GH

2
Remove cover on gearshift lever

Up to 31.08.01

AR68.20-P-2310GH

As of 01.09.01

AR68.20-P-2310GI

3
Unscrew screws (2) from front of housing (1)

4.1
Disconnect electrical connector on right and

left rear power window switches (S21/15s1

and S21/15s2)

Up to 31.08.01:

Remove wiring harness

from mount.

4.2
Disconnect connector from floor in center

console

Up to 31.08.01: Remove wiring harness

from mount.

5
Unscrew screws (4) from rear of housing (1)

6
Remove housing (1)

Set selector lever to position N


Installation:
As of 01.09.01, ensure that

air duct is installed tightly.

7
Install in the reverse order

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Page 1

BT27.60-P-0001-01A
Center shift modified
Transmission 722.6 phased in
k

TRANSMISSION
722.6

P27.60-0372-12

97
Intermediate lever

112
Selector lever

116
Shift shaft

120
Shift detent

127
Pin

128
Shift gate

128a
Rubber stop

136
Locking lever

137
Sleeve with shift detent carrier

138
Pin

138a
Roller

138b
Circlip

The center shift has been modified to improve operating convenience

and dampen noise.

The intermediate lever (97) is rigidly connected to the shift shaft (116).

A sleeve (137) with locking lever (136) is arranged on the shift shaft in

such a way that it can move.

A roller (138a) attached to the shift detent carrier and two rubber stops

(128b) on the shift gate (128) dampen noise during the transverse

movement of the selector lever.

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Page 1

AR40.10-P-1040-01A
Mounting centering sleeve

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.)
Order number

WH58.30-Z-1003-18A
Centering sleeve DUO-FLEX 2

When ordering, state flange shaft diameter and model of balancing

machine

HAWEKA

D-30928 Burgwedel

16 100 8006

WH58.30-Z-1004-18A
Conversion kit
Hofmann

D-64319 Pfungstadt

6416 451

P40.10-0212-01

1
Because of the segment centering of the rims, the wheel balancing machines approved by

Mercedes-Benz must be used with a centering sleeve (arrow).

2
The centering sleeve ensures that the rim is mounted much more securely on the balancing

machine and eliminates balancing errors.

HAWEKA centering sleeve

P40.10-0213-01

Hofmann centering sleeve

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Page 1

GF80.20-P-0005-01GH
Central locking (CL), location of components

P80.20-0522-06

Location of components
1
Antenna

F1
Fuse and relay module

F1k15
CL rear door unlocking relay

F1k20
CL all door locking relay

F1k23
CL front right front door and rear

door unlocking relay

F1k24
CL front left front door and tank

flap unlocking relay

M14/5
Right front door CL actuating

motor

M14/6
Left front door CL actuating motor

M14/7
Tailgate CL actuating motor

M14/8
Left rear door CL actuating motor

M14/9
Right rear door CL actuating motor

M14/10
Filler flap CL actuating motor

N10
All-activity module (AAM)

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Page 1

AD80.20-P-6001-43GH
CL test of electrical system motor actuation

relay

t
A

Scope of test

Measuring instrument/

Test connection
Operation/Requirement

Specified value
D

Possible cause/Remedy

1.0
Central locking locks

everything

HHT actuation

A

All doors closed and

unlocked.
All doors and

fuel tank flap

are locked
D
Individual doors are not

locked:

t
1.1

D
No door is locked:

t
1.2
1.1
Central locking unlocks

everything

HHT actuation

A

All doors closed and locked.
All doors and

fuel tank flap

are unlocked
D
Left front door and fuel

tank flap are not unlocked:

t
1.3

D
Right front door and rear

doors are not unlocked:

t
1.4

D
Tailgate is not unlocked:

t
1.5

D
No door is unlocked:

Cables, N10

1.2
Central locking relay,

lock all doors (F1k20)

Function

Replace relay (F1k20) by

relay (F1k15),

Repeat test
t
1.0

All doors and

fuel tank flap

are locked
If test 1.0 in order:
D
Relay (F1k20)

otherwise:

D
Cables

1.3
Central locking relay,

unlock left door and fuel

tank flap (F1k24)

Function

Replace relay (F1k24) by

relay (F1k15), close and

lock left front door

A
Actuation of unlocking

left front door.

Left front door

is unlocked
Value in order:

D
Relay (F1k24)

Value not in order:

D
Cables

1.4
Central locking relay,

unlock right door and

rear doors (F1k23)

Function

Replace relay (F1k23) by

(F1k15), repeat test

t
1.1

All doors and

fuel tank flap

are unlocked
If the same fault pattern

emerges when test 1.1 is

repeated:

D
Cables

D
All-Activity Module (AAM)

(N10)

Tailgate is not unlocked:

D
Relay (F1k23)

1.5
Central locking relay,

unlock tailgate (F1k15)

Function

Replace relay (F1k15) by

(F1k23), close and lock

tailgate

A
Actuation of unlocking

tailgate

Tailgate is

unlocked
Value in order:

D
Relay (F1k15)

Value not in order:

D
Cables

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Page 1

AR09.41-P-6817MM
Removing and installing charge air cooler
10.11.99

ENGINE
612.963 in MODEL 163.113

P09.41-2024-09

1
Headlamp units

2
Cover strips

3
Front end crossmember

4
Socket at temperature sensor
9

Bolts

11
Socket

110/2
Charge air cooler

B17
Intake air temperature sensor

5

Right hose clamp

6
Left hose clamp

7
Charge air hose to charge air cooler

8
Charge air hose from charge air cooler

Operation no. of operation texts or standard texts and flat rates
Sector

Op. no.
Operation text

P
096810
REMOVING AND INSTALLING CHARGE AIR COOLER

P
096820
REPLACING CHARGE AIR COOLER

P
096827
REPLACING CHARGE AIR COOLER (COOLER REMOVED)

Removing, installing

Danger!

Risk of injury
from fingers becoming


jammed or bruised
when removing and

installing and aligning hood, trunk lid, doors,

lids and sliding roof
When moving components ensure that no

body parts or limbs are in the area of motion.

AS00.00-Z-0011-01A

1
Open engine hood and position upright


Have an assistant secure hood

AR88.40-P-1000GI

2
Remove headlamp units (1)

AR82.10-P-4730GH

3
Remove front end crossmember (3)

Place over engine with release cable

attached.

AR62.30-P-2300GH

4
Unplug socket (4) at intake air temperature

sensor (B17)


Do not release or lock temperature sensor

(B17) in place with socket plugged in

otherwise the locking arms will be over-

tensioned. Refer to:

#

Removing and installing intake air

temperature sensor.

AR07.52-P-1465A

5
Detach hose clamps (5, 6) of the charge air

hoses (7, 8) at the charge air cooler (110/2)

6
Unscrew bolts (9) at charge air cooler

7
Remove charge air cooler (110/2)

Detach from charge air hoses.
Traces of oil, slight quantities of oil in the

charge air hose come from the crankcase

ventilation and are permissible.

8
Install in the reverse order

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1